A Synopsis on

High Voltage Testing of Transformers

Submitted by

Adnan Iqbal

M. Tech

(T16EE015)

Department of Electrical Engineering

NATIONAL INSTITUTE OF TECHNOLOGY
MEGHALAYA
SHILLONG -793003
(2017)
Introduction

A transformer is a static device that transfers electrical energy from one circuit to another through
inductively coupled conductors the transformer's coils. A varying current in the first or primary
winding creates a varying magnetic flux in the transformer's core and thus a varying magnetic field
through the secondary winding. This varying magnetic field induces a varying electromotive force
(EMF) or "voltage" in the secondary winding. This effect is called mutual induction.

If a load is connected to the secondary, an electric current will flow in the secondary winding and
electrical energy will be transferred from the primary circuit through the transformer to the load. In an
ideal transformer, the induced voltage in the secondary winding (Vs) is in proportion to the primary
voltage (Vp), and is given by the ratio of the number of turns in the secondary (Ns) to the number of
turns in the primary (Np) as follows:

By appropriate selection of the ratio of turns, a transformer thus allows an alternating current (AC)
voltage to be "stepped up" by making Ns greater than Np, or "stepped down" by making Ns less than
Np. In the vast majority of transformers, the windings are coils wound around a ferromagnetic core,
air-core transformers being a notable exception.

Transformers range in size from a thumbnail-sized coupling transformer hidden inside a stage
microphone to huge units weighing hundreds of tons used to interconnect portions of power grids. All
operate with the same basic principles, although the range of designs is wide. While new technologies
have eliminated the need for transformers in some electronic circuits, transformers are still found in
nearly all electronic devices designed for household ("mains") voltage. Transformers are essential for
high-voltage electric power transmission, which makes long-distance transmission economically
practical.

High voltage transformer

High voltage transformers convert voltages from one level or phase configuration to another, usually
from higher to lower. They can include features for electrical isolation, power distribution, and control
and instrumentation applications. High voltage transformers usually depend on the principle of
magnetic induction between coils to convert voltage and/or current levels.

Other important specifications to consider when searching for high voltage transformers include
maximum secondary voltage rating, maximum secondary current rating, maximum power rating, and
output type. A transformer may provide more than one secondary voltage value. The Rated Power of
the transformer is the sum of the VA (Volts*Amps) for all of the secondary windings. Output choices
include AC or DC. For Alternating Current waveform output, voltage the values are typically given in
RMS values. Consult manufacturer for waveform options. For direct current secondary voltage
output, consult manufacturer for type of rectification.

High voltage transformers can be constructed as either a toroidal or laminated transformer. Toroidal
transformers typically have copper wire wrapped around a cylindrical core so the magnetic flux,
which occurs within the coil, doesn't leak out, the coil efficiency is good, and the magnetic flux has
little influence on other components. Laminated transformers contain laminated-steel cores; they are
also called E-I transformers. These steel laminations are insulated with a non-conducting material,
such as varnish, and then formed into a core that reduces electrical losses. Power transformers can be
one of many types. These include autotransformer, control transformer, current transformer,
distribution transformer, general-purpose transformer, instrument transformer, isolation transformer,
potential (voltage) transformer, power transformer, step-up transformer, and step-down transformer.
Mountings available for high voltage transformers include chassis mount, dish or disk mount,
enclosure or free standing, h frame, and PCB mount

Testing of transformer

As regards complex electrical equipment such as high voltage power transformers, internal insulation
is subject to defects due to several reasons associated to bad material, design, manufacturing
processes or resulting from shipment. On-site electrical tests are for the test voltage to simulate on the
transformer under testing the equivalent stresses which may be established during service condition.
Basically, electrical tests on power transformers are grouped in type and routine tests. The goal of a
routine test is to check correct manufacture of HV insulation while the goal of a type test is to confirm
correct design of HV insulation. In addition, the application of on-site tests may be able to be
separated in:
1- Commissioning tests: as part of the on-site equipment commissioning procedure in order to
demonstrate that shipment and erection have not caused any new defects to HV insulation.
2- On-site repair or refurbishment: as part of the repair or refurbishment procedure in order to
demonstrate that repair or refurbishment have been successfully completed and HV insulation
is free of dangerous defect.
3- Diagnosis: as part of a diagnostic procedure in order to provide reference values to further
tests or to confirm results obtained from other types of test.
Up to date, on-site high voltage withstands tests including partial discharge monitoring and
measurements are the most significant tests in order to quantify HV insulation quality. The use of a
separate HV source is more informative than measurement at normal operation voltage, as it allows
investigation of the HV insulation performance with voltage.
Alternating voltages are most important for on-site tests. Other voltage shapes for simulation of
overvoltages have been used; however, they are strongly dependent on availability of on-site testing
systems.
The application of HV on-site tests has been a good practice in South America. Since 1992, on-site
HV tests have been performed in more than 110 power transformers ranging from 30MVA to
550MVA, 115kV to 765kV (AC) and 600kV (DC). Large electric power utilities and industrial plants
are the main customers to this technology.

HV on-site test setup

To perform HV on-site tests, a complete set of mobile testing equipment is made available at field,
including:
1- Variable frequency 60-240Hz motor-generator group. There are three motor-generator groups
available: 300kVA, 850kVA and 2MVA. The proper group is selected according to
transformer power and voltage.
2- Step-up and regulating transformers.
3- Reactive power compensating capacitors and reactors.
4- No-load and load measuring system.
5- Partial discharges measuring and monitoring system as per IEC60076-3 and IEC60270.
HV ON-SITE TESTS APPLIED FOR DIAGNOSIS
In many cases, HV on-site tests have been used for diagnostic purposes on large power transformers.
The process of this application typically starts based on previous events such as:
1- Detected event of in oil dissolved gas generation increase given up partial discharge as a
possible diagnosis using dissolved gas analysis methods.
2- Detected mechanical event such as over acceleration during a shipment operation.
In several cases, HV induced voltage with partial discharge electrical and acoustic monitoring has
been successfully used to detect and locate partial discharge in large power transformers. As an
example, figure 4 shows a 4-year old 300MVA, 550/138/13.8kV on-load regulating transformer under
on-site testing at a substation yard.
During the test, partial discharge activities were measured (up to 7500 pC at 130% Un) and located in
the HV winding exit areas. Figure 5 shows the results of PD location through the application of 3
acoustic sensors.

The transformer has been visually inspected internally and partial discharges evidences have been
located in the area indicated by the previous test induced test. After that, the transformer has been
shipped back to factory and disassembled for complete repair.

Impulse Voltage Test of Transformers

During the Lightning Impulse (LI) test of transformer windings with low impedance it is difficult to
ensure a minimum time to half-value of 40 s in accordance with IEC 60076-3 and IEC 60060-1. This
is caused by the oscillating discharge determined by the impulse voltage test generator capacitance
and the transformer impedance. In most cases using special adapted circuits can solve the problem.
1. Impulse voltage test generator with capacitive load
For the LI testing of basic arrangements but also of different electrical components a purely capacitive
load can be assumed. The impulse voltage shape generated by an impulse voltage test generator based
on the MARX multiplier circuit can be described by two exponential functions with different time
constants. Whereas the LI front time T1 according to IEC 60060-1 [1] is essentially determined by the
resistance of the front resistor Rs located in the impulse voltage test generator and the load
capacitance Ct, see fig. 1, the time to half-value T2 is determined by the impulse capacitance of the
impulse capacitor Ci and the resistance of the tail resistor Rp being part of the impulse voltage test
generator. According to IEC 600060-1 there are the following time parameters and tolerances for the
standard LI 1.2/50: Front time T1 = 1.2 s + 30 % Time to half-value T2 = 50 s + 20 %.

Impulse voltage test generator with inductive load

In most of the cases power transformers cannot be assumed as a purely capacitive load for the LI
testing. Usually the LI test voltage is applied to one winding terminal of the transformer to be tested,
whereas all other terminals are connected with the earth. Hereby, not only the input capacitance of the
transformer winding acts as the load for the impulse voltage test generator but also its impedance to
all other short-circuited windings. The principal circuit (fig. 1) must be extended by the transformer
inductance Lt that is connected in parallel to the test capacitance Ct.
Thereby the inductance Lt of the load becomes smaller with decreasing impedance voltage vimp %,
with decreasing rated phase-to-phase voltage Vp-p and with increasing power Ptot of the transformer
winding to be tested. Therefore the lowest values of the inductance Lt have to be considered by testing
the low-voltage side windings for power transformers. For a three-phase winding in a star connection
the following equation can be applied: Lt Inductance (stray inductance) of the winding to be tested
Impedance voltage of the winding to be tested Vp-p rated phase-to-phase voltage of the three-phase
winding to be tested Ptot Rated total power of the three-phase winding to be tested f rated frequency
with decreasing inductance Lt the impulse capacitance Ci of the impulse voltage test generator is not
only discharged via the tail resistor Rp, but also via the low inductance Lt of the winding to be tested.
Thereby the time to half-value T2 of the LI is reduced and the aperiodic discharge of the impulse
capacitance turns to a damped oscillating cosine shape. This is permitted in principle acc. to IEC
60076-3 [2]. However, the lower tolerance limit for the time to half-value of T2 min may not remain
under 40 s. At the other side the amplitude of opposite polarity of the LI voltage dmax should not
exceed 50 %. To fulfil these both requirements the impulse voltage impulse voltage test generator
must have a minimum required impulse capacitance.

Projection of an impulse voltage test generator for the LI test of power transformers
The main technical data of the transformers to be tested, like the circuitry and the arrangement of the
windings, their rated voltage, rated power, impedance voltage and not at least the rated frequency
determine essentially the total charging voltage and the stage energy of an impulse voltage test
generator for the LI test. The total charging voltage of the impulse voltage test generator should lie for
LI testing 30 % to 60 % above the highest required LI test voltage. In many cases the value of 30 % is
sufficient for routine tests. If development tests are to be carried out, a total charging voltage, which
lays 60 % above the highest rated LI test voltage, is recommended. If the exception earthing via
termination resistors is not considered, the required impulse capacitance Ci req can be calculated for
each winding voltage level acc. to equation (5). Taking into consideration the different circuitry
options of the impulse voltage test generator (parallel connection of stages, partial operation) and the
above aspects regarding the total charging voltage the stage charging energy can be calculated in
principle for each possible test case. Normally a stage energy of 5 to 10 kJ per 100- kV-stage and a
stage energy of 10 to 20 kJ per 100 kV stage.
200-kV-stage will be sufficient. Whereas the lower values apply to transformers with lower power,
the higher values apply to transformers with higher power (fig. 4). Often, impulse voltage test
generators for power transformer testing have energy of 15 kJ per 200-kV-stage.

Extension of the loading range of impulse voltage test generators

Often it is required to test transformer with such a high power, for which the existing impulse voltage
test generator has not been originally meant. In such cases it is necessary to utilise all reserves of the
existing impulse voltage test generator.

Increasing the effective impulse capacitance

The following generally known measures can be taken:

a) Running the impulse voltage test generator in partial operation, i.e. with the minimum number of
stages, being necessary to reach the required test voltage level.

b) Switching a certain number of generator stages respectively in parallel and connect this parallel
stages in series to reach the required test voltage.

Increasing the parallel resistors

If the time to half-value remains only a few below the permitted lower limit T2 min = 40 s, it is
possible to reach a value of T2 40 s by increasing the tail resistors Rp. Usually the tail resistors
meant for switching impulse voltage can be applied. A further increase of the resistance of the tail
resistors Rp above the resistance value for the S.I. generation does not have any result.
 Fig. 5: Impulse Voltage Test System IP 150/2000 G (150 kJ, 2000 kV) with impulse voltage divider
and chopping multiple spark gap, with a stage energy of 15 kJ being used for the LI test of power
transformers up to 245 kV.

5.3. Decreasing the damping of the test circuit

As already mentioned in chapter 2, if the circuit damping is to high, a time to half-value of T2 40 s
is not reached even with a sufficient of the impulse voltage test generator (Ci Ci req), see fig. 3. The
front and tail resistors in the impulse voltage test generator are mostly responsible for that damping.
The damping caused by the tail resistors Rp can be considerably eliminated by their increase, as
already recommended in chapter 5.2. For a further reduction of the damping the resistance of the front
resistor Rs has to be reduced. This would cause a shorter front time T1 of the LI. To keep the front
time T1 unchanged, the capacitance of the load has to be increased corresponding to the reduction of
the resistance of the front resistor Rs. This is easily realised by connecting an additional capacitor in
parallel to the transformer winding to be tested. Unfortunately, the effect of this method is limited,
because a reduction of the resistance of the front resistor Rs will lead to oscillations on the front of the
LI voltage soon, which may exceed the permitted limit for the overshoot of 5 %.

Application of the Glaninger-circuit

The disadvantage of oscillations on the voltage front after a reduction of the front resistor R s is
completely avoided with a circuit invented by Glaninger. Hereby the front resistor responsible for the
voltage front remains unchanged but it is bridged by an additional inductance formed by an air-coil.
The Glaninger-coil must have an inductance value of 100 to 200 H, to be ineffective for the fast
impulse front and to bridge the front resistor Rs during the much longer impulse tail. So the front of
the LI impulse remains unchanged and the tail is extended. Consequently an additional resistor Rt has
to be switched in parallel to the load inductance Lt, to form a true voltage divider consisting of Rs//Lg
and Rt//Lt

Fig. 7: LI test of power transformers by using the Glaninger-circuit, adjustment of the voltage shape at
the voltage crest by means of an additional resistor Rt (optimal adjustment Rt = 300 ohm for this
example)
Fig. 8: LI test of power transformers by using the Glaninger-circuit, adjustment of the time to half-
value T2 and the amplitude of opposite polarity d by means of the tail resistor Rp (optimal adjustment
Rp = 60 Ohm for this example, T2 > 40 s, d < 50 %) With a Glaninger-circuit the front time T1, the
time to half-value T2 and the amplitude of opposite polarity d of the LI test voltage can be set almost
independently, i.e. T1 with the tail resistor Rs, T2 and d with the resistors R p und Rt (fig. 7 and 8). A
variation of the Glaninger-coil inductance is as a rule not necessary. The Glaninger circuit enables for
LI testing the most effective adaptation of the impulse voltage test generator and the transformer to be
tested. An existing impulse voltage test generator can be utilised optimally.

6. Conclusion
The testing of power transformers with LI test voltage acc. to the IEC standards presupposes special
knowledge of the interaction between the impulse voltage test generator and the inductive load. For
example, there exists a close connection between the main data of the transformer to be tested and the
required impulse capacitance of the impulse voltage test generator. There are also requirements
related to the damping characteristic of the test circuit to utilise an existing impulse voltage test
generator optimally. Some basic aspects and circuitries were described in this report.
1- Oxidation of oil: Oxidation usually results in the formation of acids and sludge in the
transformer liquid. It is mainly due to exposure to air and high operating temperatures.
2- Pressure-relief diaphragm broken: This is due to an internal fault causing excessive internal
pressures or the transformer liquid level being too high or excessive internal pressure due to
loading of transformer.
 3- Discoloration of transformer liquid: Discoloration is mainly caused by carbonization of the
liquid due to switching, core failure, or contaminations.
4- Leakage of transformer liquid: Leakage can occur through screw joints, around gaskets,
welds, casting, pressure-relief device, and so on. The main causes are improper assembly of
mechanical parts, improper filters, poor joints, improper finishing of surfaces, defects in the
material used, or insufficient tightness of mechanical parts.
5- Moisture condensation: The main causes for moisture condensation are improper ventilation
in open-type transformers and a cracked diaphragm or leaking gaskets in sealed-type
transformer.
6- Gas-sealed transformer troubles: In gas-sealed transformers, additional problems can be the
loss of gas, oxygen content above 5%, or gas regulator malfunctions. These problems are
caused by gas leaks above the oil, leaky valve seats, insufficient gas space, and/or insufficient
flushing of gas space with nitrogen.
7- Transformer switching equipment troubles: Many transformers are equipped with tap
chargers and other switching equipment. The problems associated with these transformers
may be excessive wearing of contacts, mechanism over travel, moisture condensation in
mechanism liquid, and others.
Excessive contact wear is due to loss of contact pressure from weakened springs or a contact-making
voltmeter set at too narrow a bandwidth or insufficient time delay. Mechanism over travel usually is
due to defective or improper adjustment of controller contacts. Moisture condensation is due to
improper ventilation, and carbonization is due to excessive operation and lack of filtering. Other
problems such as control fuse blowing and mechanism motor stalling are due to short circuits in the
control circuit, mechanical binding, or low-voltage conditions in the control circuitry

A.C. Hi-Pot Test

The AC hi-pot test is applied to evaluate the condition of transformer windings. This test is
recommended for all voltages, especially those above 34.5 kV. For routine maintenance testing of
transformers, the test voltage should not exceed 65% of factory test voltage. However, the hi-pot test
for routine maintenance is generally not employed on transformers because of the possibility of
damage to the winding insulation. This test is commonly used for acceptance testing or after repair
testing of transformers. The AC HV test value should not exceed 75% of the factory test value. When
AC hi-pot testing is to be used for routine maintenance, the transformer can be tested at rated voltage
for 3 min instead of testing at 65% of factory test voltage. The AC hi-pot test values for voltage
systems up to 69 kV are shown in Table 5.9. Testing procedures and test connections are similar to
the DC hi-pot tests
TTR Test
The TTR test applies voltage to one winding of a transformer and detects the voltage being generated
on another winding on the same core. In the case of a low voltage hand-crank powered TTR, 8 V AC
is applied to the low-voltage winding of the transformer under test and a reference transformer in the
TTR set. The HV windings of the transformer under test and the TTR reference transformer are
connected through a null detecting instrument. After polarity has been established at 8 V, when the
null reading is zero, the dial readings indicate the ratio of the transformer under test.
In the case of an electronic TTR test set, a voltage (typically 80 V AC) is applied to the HV winding
of the transformer under test. The voltage generated on the low-voltage winding is measured and the
voltage ratio between high and low windings is calculated. Voltage ratio is proportionally equal to
turns ratio. The hand-crank powered TTR, the handheld electronic TTR, and the three-phase
electronic TTR are through c, respectively.
The TTR test provides the following information:
1- It determines the turn ratio and polarity of single and three-phase transformers, one phase at a
time.
2- It confirms nameplate ratio, polarity, and vectors.
3- It determines the ratio and polarity (but not voltage rating) of transformers without markings.
Tests include all no-load tap positions on a transformer. Tests include all load taps on load; tap
changer (LTC) transformers if connected for voltage ratio control. On LTC transformers connected
for phase angle control, ratio and polarity are performed in neutral positions only. If tested on load
taps, readings may be taken for reference for future comparison, but will deviate from nameplate
ratings. LTC taps may be confirmed by application of low three-phase voltage and reading volts and
the phase angle for each.
Identify trouble in transformer windings, such as open-circuit and short-circuits of turn-to-turn
sensitivity. The standard deviation as defined by ANSI/IEEE C57.12.00-2006, Section 9.1 states that
results should be within 0.5% of nameplate markings, with rated voltage applied to one winding. The
TTR with accuracy of 0.1% is accepted as a referee.